Two-shot knuckles for coupling electrically isolated sections of an electronic device and methods for making the same

ABSTRACT

Two shot knuckles include a first shot component and a second shot component. Both shot components are composed of different dielectric materials, where the first shot is composed of a relatively high strength structural material and the second is composed of a cosmetic material. The first shot component can physically couple two conductive sections together by interfacing with a coupling structure of that section. The first shot component includes second shot retaining regions and a cosmetic region. The second shot component occupies the cosmetic region and anchors itself to the first shot component using the second shot retaining regions. The second shot may be the only part of the two-shot knuckle visible to a user of an electronic device and can exhibit any desired color.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation patent application of U.S. patentapplication Ser. No. 16/565,033, filed Sep. 9, 2019 and titled “Two-ShotKnuckles for Coupling Electrically Isolated Sections of an ElectronicDevice and Methods for Making the Same,” which is a continuation patentapplication of U.S. patent application Ser. No. 16/134,898, filed Sep.18, 2018 and titled “Two-Shot Knuckles for Coupling ElectricallyIsolated Sections of an Electronic Device and Methods for Making theSame,” now U.S. Pat. No. 10,439,271, which is a continuation patentapplication of U.S. patent application Ser. No. 15/678,704, filed Aug.16, 2017 and titled “Two-Shot Knuckles for Coupling ElectricallyIsolated Sections of an Electronic Device and Methods for Making theSame,” now U.S. Pat. No. 10,290,926, which is a continuation patentapplication of U.S. patent application Ser. No. 14/659,689, filed Mar.17, 2015 and titled “Two-Shot Knuckles for Coupling ElectricallyIsolated Sections of an Electronic Device and Methods for Making theSame,” now U.S. Pat. No. 9,755,296, which is a continuation patentapplication of U.S. patent application Ser. No. 13/251,026, filed Sep.30, 2011 and titled “Two-Shot Knuckles for Coupling ElectricallyIsolated Sections of an Electronic Device and Methods for Making theSame,” now U.S. Pat. No. 9,007,748, which claims the benefit of U.S.Provisional Patent Application No. 61,529,728, filed Aug. 31, 2011 andtitled “Two-Shot Knuckles for Coupling Electrically Isolated Sections ofan Electronic Device and Methods for Making the Same,” the disclosuresof which are hereby incorporated herein by reference in theirentireties.

FIELD

Systems and methods are disclosed for coupling sections of an electronicdevice. In particular, components of an electronic device can beassembled from two or more sections, where these sections may be coupledtogether using two-shot knuckles.

BACKGROUND

A portable electronic device can be constructed using differentapproaches. In some cases, an electronic device can be constructed byassembling several components together. These “components” can includeexternal components that are combined to form a device enclosure (e.g.,a device “housing”), as well as internal components that may providestructural support or other functionality for the electronic device(e.g., the internal component could be a microchip). Based on the designof the electronic device, the components can be formed from any suitablematerial(s) such as metals, plastics, or any other materials.

In some cases, the various components of the electronic device canoperate as part of an electrical circuit. For example, a particularcomponent could serve as a resistor or as a capacitor to another part ofthe electronic device. As another example, a component can function aspart of an antenna assembly of the electronic device. If the componentis used in only a single electrical circuit, then the component may beconstructed from a single piece of conductive material. If the samecomponent, however, is used in several different electrical circuits,the component may need to be constructed from several “sections” ofconductive elements. In this case, however, it may be necessary toseparate each of the conductive sections with an insulating or othernon-conductive material, in order to ensure that each section operatesin its own electrical circuit correctly. In some cases, it may bedesirable for this insulating material to exhibit desired cosmeticproperties as well as perform its functional duties of coupling thesections together and electrically isolating them.

SUMMARY

Two-shot knuckles for coupling electrically isolated conductive sectionsof an electronic device and methods for making the same are provided. Insome embodiments, an electronic device can be formed from severalcomponents, such as an outer periphery component and/or othercomponents. The outer periphery component may provide a housingstructure for the electronic device by encircling the electronic device.In some cases, this outer periphery component can be assembled from twoor more “sections.” Knuckles may then be used to couple these sectionstogether.

The shape and structure of the knuckles can be based on various designconsiderations. Two shot knuckles include a first shot component and asecond shot component. Both shot components are composed of differentdielectric materials, where the first shot is composed of a relativelyhigh strength structural material and the second is composed of acosmetic material. The first shot component can physically couple twoconductive sections together by interfacing with a coupling structure ofeach section. The first shot component includes second shot retainingregions and a cosmetic region. The second shot component occupies thecosmetic region and anchors itself to the first shot component using thesecond shot retaining regions. The second shot may be the only part ofthe two-shot knuckle visible to a user of an electronic device and canexhibit any desired color.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention, its nature andvarious advantages will be more apparent upon consideration of thefollowing detailed description, taken in conjunction with theaccompanying drawings in which:

FIG. 1 shows a schematic view of an illustrative component of anelectronic device in accordance with some embodiments of the presentinvention;

FIGS. 2A-G show several views of an illustrative bracket in accordancewith some embodiments of the invention;

FIGS. 2H-2N show several views of another illustrative bracket inaccordance with some embodiments of the invention;

FIGS. 3A and 3B show illustrative views of a bracket welded to a sectionin accordance with some embodiments of the invention;

FIG. 4 shows an illustrative view of another bracket welded to a sectionin accordance with some embodiments of the invention;

FIGS. 5A and 5B show various views of a particular knuckle design inaccordance with one embodiment of the invention;

FIGS. 6A-6C show various schematic views of another particular knuckledesign in accordance with one embodiment of the invention;

FIG. 7 shows a cross-sectional view of the knuckle of FIG. 6A inaccordance with one embodiment of the invention;

FIGS. 8A-8C show various schematic views of yet another particularknuckle design in accordance with one embodiment of the invention;

FIG. 9 shows a two-shot knuckle according to some embodiments of theinvention;

FIG. 10 shows a cross-sectional view of the knuckle of FIG. 9 takenalong line A-A in accordance with an embodiment of the invention;

FIGS. 11A-B, 12A-B, 13A-B, and 14A-B show illustrative views of a seriesof process steps used to manufacture a two-shot knuckle in accordancewith some embodiments of the invention; and

FIG. 15 shows an illustrative process for mechanically coupling twoconductive sections together with a two-shot knuckle in accordance withsome embodiments of the invention.

DETAILED DESCRIPTION

An electronic device can include several components assembled togetherto form internal and/or external features of the electronic device. Forexample, one or more internal components (e.g., electrical circuitryand/or internal support structures) can be placed within externalcomponents (e.g., housing structures) to provide an electronic devicehaving desired functionality. As used herein, the term “component”refers to a distinct entity of an electronic device, such as aparticular electronic circuit (e.g., a microchip), a member forming thehousing of the electronic device (e.g., a backplate, an outer peripherycomponent, and the like), an internal support structure (e.g., amid-plate), and the like.

In some cases, a component can be manufactured by assembling andconnecting two or more different individual elements (i.e., “sections”)together. As used herein, the term “section” refers to an individualportion of a component, where that component may be formed from multiplesections. The various sections of the component may then be coupledtogether using a “knuckle.” Based on the desired functionality anddesign of the component and its sections, these knuckles can exhibit awide range of shapes and structures. For example, the knuckles caninclude structural designs that reinforce the knuckle at areas of highmechanical strain, that counteract twisting movements at areas of hightorsion, that interlock two sections together such that they aremechanically coupled together, that provide electrical isolation betweenthe sections, and the like.

FIG. 1 shows a schematic view of an illustrative component of anelectronic device in accordance with some embodiments of the presentinvention. In particular, FIG. 1 shows outer periphery component 100that can be constructed by connecting several sections together, such assections 110, 120, 130, and 140. Outer periphery component 100 can beconstructed to form an exterior, periphery surface for an electronicdevice. In particular, outer periphery component 100 can surround orwrap around some or all of the internal components (e.g., electroniccircuits, internal support structures, and the like) of the electronicdevice. In other words, outer periphery component can define an internalvolume into which internal components can be placed.

The thickness, length, height, and cross-section of outer peripherycomponent 100 can be selected based on any suitable criteria including,for example, based on structural requirements (e.g., stiffness orresistance to bending, compression, tension or torsion in particularorientations). In some embodiments, outer periphery component 100 canserve as a structural member to which other electronic device componentscan be mounted. Some of the structural integrity of outer peripherycomponent 100 can come from the closed shape that it defines (e.g.,outer periphery component 100 forms a loop, thus providing structuralintegrity).

Outer periphery component 100 can have any suitably shapedcross-section. For example, outer periphery component 100 can have asubstantially rectangular cross-section. Each corner of thesubstantially rectangular cross-section can be rounded in shape, thusforming a “spline.” As used herein, the term “spline” refers to arounded corner portion of an outer periphery component. In someembodiments, outer periphery component 100 can have a cross-section inany other suitable shape including, for example, a circular shape, anoval shape, a polygonal shape, or a curved shape. In some embodiments,the shape or size of the cross-section of outer periphery component 100can vary along the length or width of the electronic device (e.g., anhourglass shaped cross-section).

Outer periphery component 100 of the electronic device can beconstructed using any suitable process. In some embodiments, outerperiphery component 100 can be constructed by connecting section 110 andsection 120 together at interface 112, connecting section 120 andsection 130 together at interface 122, connecting section 130 andsection 140 together at interface 132, and connecting section 140 andsection 110 together at illustrated in FIG. 1 as being constructed fromfour sections, one skilled in the art could appreciate that outerperiphery component 100 could alternatively be formed from any suitablenumber of two or more sections, and that the interfaces between thesections may be positioned at any location on outer periphery component100.

Each section 110, 120, 130, and 140 can be constructed individually andlater assembled to form outer periphery component 100. For example, eachsection can be individually constructed using one or more of stamping,machining, working, casting, or any combinations of these. In someembodiments, the materials selected for sections 110, 120, 130, and 140can be conductive, thus allowing the sections to provide an electricalfunctionality for the electronic device. For example, sections 110, 120,130 and/or 140 can be formed from a conductive material such asstainless steel or aluminum. In some embodiments, each section may serveas an antenna for the electronic device.

To mechanically couple individual sections together, knuckles 114, 124,134, and 144 can exist at interfaces 112, 122, 132, and 134respectively. In some embodiments, each of the knuckles can beconstructed from a material that can begin in a first state and maysubsequently change to a second state. As an illustration, the knucklescan be constructed from a plastic that begins in a first, liquid stateand then subsequently changes to a second, solid state. While in theliquid state, the plastic can be allowed to flow into interfaces 112,122, 132, and 142. After flowing into these interfaces, the plasticmaterial may subsequently be allowed to harden into knuckles 114, 124,134, and 144 (e.g., the plastic material is allowed to change into thesecond, solid state). Upon changing into the solid state, the plasticmaterial may then bond together sections 110 and 120, 120 and 130, and140 and 110, respectively, thus forming a single new component (e.g.,outer periphery component 100). In one embodiment, knuckle 134 may becosmetic and not physically couple sections 130 and 140 together. Inthis embodiment, sections 130 and 140 can be welded together so thatthey are physically and electrically coupled. In another embodiment,knuckle may physically couple sections 130 and 140 together inaccordance with principles of the invention.

Knuckles 114, 124, and 144 not only physically couple together sections110 and 120, 120 and 130, and 140 and 110, respectively, theyelectrically isolate section 110 from section 120, section 120 fromsection 130, and section 140 from section 110. For purposes of thisdiscussion, assume sections 130 and 140 are electrically the samebecause they are welded together, and that knuckle 134 is cosmetic. Aswill be explained in more detail below, knuckles 114, 124, and 144encapsulate and/or exist with coupling structures that are attached toor integrally formed parts of sections 110, 120, 130, and 140. That is,when the knuckle in its first state (e.g., the liquid state), it flowsinto and/or around the coupling structures. A shutoff device (not shown)may be positioned at each interface to shape the knuckle for when ittransforms into its second state (e.g., the solid state). As shown inFIG. 1, knuckles 114 and 124 are asymmetric in shape and knuckle 144 issymmetric in shape.

The coupling structures (not shown) exist on sections 110, 120, 130, and140. Some sections (e.g., sections 110 and 120) may have two couplingstructures whereas other sections (e.g., sections 130 and 140) have onecoupling structure for interfacing with a knuckle. In some embodiments,the coupling structure can be a bracket such as that shown, for example,in FIG. 2. The bracket can be attached or welded to an inside surface ofa section. In another embodiment, the coupling structure can be anintegrally formed part of the section that was originally part of thesection. In FIG. 1, knuckle 114 interfaces with a bracket and anintegrally formed coupling structure and knuckles 124 and 144 interfacewith two brackets.

Any suitable process can be used to place the knuckle material intointerfaces 112, 122, 132, and 142, and any suitable process can be usedto change the knuckle material from the first state to the second state.In some embodiments, a “molding process” can be used in which theknuckle material is initially inserted in a liquid state and then issubsequently hardened. For example, one or more of injection molding,compression molding, transfer molding, extrusion molding, blow molding,thermoforming, vacuum forming, or rotomolding processes can be used. Inthis case, a “one shot” process can be used in which the knucklematerial is inserted in a single step, and then independently changes toits second state. In other words, the knuckle can be formed in a singlestep (e.g., in “one shot”) without necessitating additional steps ormanufacturing processes.

The knuckle material may be any material suitable for mechanicallycoupling two sections together and electrically isolate the two section.The knuckle material may be a plastic such as a thermal plastic. In oneembodiment, the knuckle material may be a glass filled nylon.

FIGS. 2A-G show several views of an illustrative bracket 200 inaccordance with an embodiment of the invention that can be mounted toone of the sections. In particular, FIGS. 2A-G show back, top, front,left, right, bottom, and isometric views respectively of bracket 200.Bracket 200 can include three legs 210, 220, and 230, which extend fromplanar member 240. Legs 210 and 220 may both extend away from planarmember 240 at a right angle (e.g., 90 degrees), whereas leg 230 mayextend away from leg 230 at angle between 1 and 90 degrees. Leg 230 canhave slot 232 to promote flow of knuckle material when it is in itsfirst state. In addition, plate 240 can have through-hole 242 or acutout of any suitable shape to promote flow of knuckle material when inits first state. Legs 210, 220, and 230 may have feet 214, 224, and 234,respectively, for being welded to a surface of one of the sections.

Bracket 200 can be constructed from any suitable material. In someembodiments, bracket 200 is constructed from a conductive material suchas metal (e.g., steel or aluminum). In some embodiments, bracket 200 isconstructed from the same material as the section it is being welded to.For example, bracket 200 and the section it is being welded to can bothbe constructed from stainless steel.

It is understood that brackets of any suitable construction can be usedin connection with the sections. For example, FIGS. 2H-2N shows severalviews of bracket 250 constructed in accordance with an embodiment of theinvention. Bracket 250 is similar in many respects to bracket 200 as itincludes legs and welding feet, as well as a cutout for promotingknuckle material flow.

Referring now to FIGS. 3A and 3B, illustrative views of bracket 200welded to section 300 are shown. In particular, FIG. 3A shows anillustrative cross-sectional view and FIG. 3B shows an illustrative topview. Bracket 200 is shown sitting within recess 310 of section 300.Recess 310 may have been machined out of section 300 during or aftermanufacture of section 300. Recess 310 may serve as a vessel forretaining a portion of a knuckle as it transitions from its first tosecond state. As shown, feet 214, 224, and 234 are welded to recess 310.This weld physically anchors bracket 200 to section 300 and electricallycouples bracket to section 300.

The edge of bracket 200 aligns with the edge of section 300. Thisalignment may be a product of a cutting operation that physically cutsaway a portion of bracket 200 and section 300. It is the totalcross-sectional area of the aligned edges of bracket 200 and section 300that control capacitance of the knuckle coupling two sections together.Smaller cross-sections generally result in less capacitance. Inembodiments where the section is used as an antenna, lower capacitanceenhances antenna performance. The cross-sectional area can be varied,for example, by increasing the thickness of bracket 200 or using abracket that has a different cross-sectional shape. See FIG. 4 as anexample of another bracket 400 having a different cross-sectional shape.

FIG. 5A shows an illustrative enlarged perspective view of sections 110and 140 (of FIG. 1) having respective brackets 200 welded thereto inaccordance with an embodiment of the invention. FIG. 5A also showscontact members 520 and 540 welded to top of the planer member of eachbracket 200. Contact members 520 and 540 have a cutout that mimicscutout 242 of bracket 200 and that promotes flow of knuckle materialwhen it is in its first state. A portion of contact members 520 and 540will be left exposed after the knuckle material encapsulates brackets200 and members 520 and 540. The exposed portion may provide a solderpad for connecting a conductor (e.g., an antenna conductor) so that itis electrically coupled to one of sections 120 or 140.

Gap 510 exists between the side walls of sections 110 and 140. Gap 510may have a predetermined distance that is maintained between the sidewalls and brackets 200 during application of the knuckle material. Whenthe material is applied, it can flow in and around brackets 200, members520 and 540, and fill the recesses in which brackets 200 sit. After thematerial cures, resulting knuckle 144 (FIG. 5B) is provided.

FIG. 5B shows a perspective view of knuckle 144 in accordance with anembodiment of the invention. As shown, knuckle 144 physically couplessections 110 and 140 together but ensures they are electrically isolatedby the distance of gap 510. Portions of contact members 520 and 540 areexposed even though knuckle 144 is cured. It is understood that contactmembers 520 and 540 are optional and are not necessary for each knuckle.For example, knuckle 124 may not encapsulate any contact members.

FIG. 6A shows a perspective view of knuckle 124 of FIG. 1 in accordancewith an embodiment of the invention. Knuckle 124 can encapsulate twobrackets (not shown) and mechanically couple sections 130 and 120together, and ensures they are electrically isolated by gap 710. FIGS.6B and 6C show a perspective view and a top view, respectively ofbrackets 200 and 250 mounted to sections 120 and 130, respectively.Bracket 250 is dimensioned a little smaller than its counterpart bracket200 and thus may be better suited for being mounted in curved sections,such as section 120.

FIG. 7 shows a cross-sectional view taken along line A-A of FIG. 6A. Thecross-sectional view shows side wall 732 of section 130, knuckle 124,and bracket 200. Also shown is vertical center axis 701 which is alignedwith plate member 240. Horizontal center axis 702 is also shown tobisect plate member 240. Equal thicknesses of knuckle 124 exist on bothsides of center axes 701 and 702. This ensures knuckle 124 is evendistributed about the bracket and provides optimal mechanical couplingstrength.

FIGS. 8A-C show various illustrative views of interface 112 inaccordance with embodiments of the invention. FIG. 8A shows bracket 250mounted to section 120 and it also shows integrated coupling structure850. FIGS. 8B and 8C show knuckle 114 interfacing with bracket 250 andcoupling structure 850.

FIG. 9 shows a two-shot knuckle according to an embodiment of theinvention. As shown, two-shot knuckle 910 mechanically couples togethersections 920 and 930. Sections 920 and 930 can be any suitableconductive section each having a coupling structure (e.g., a bracketwelded thereto or an integrally formed structure). For example, sections920 and 930 can each have a bracket welded thereto. As another example,section 920 can have a bracket welded thereto and section 930 can havean integrally formed structure. In yet another example, both sections920 and 930 can have integrally formed structures.

Two-shot knuckle 910 includes first shot component 912 and second shotcomponent 918. First shot component 912 physically couples sections 920and 930 together. That is, first shot 912 provides the mechanicalcoupling since it encapsulates both coupling structures similar to thatas discussed above in connection with FIGS. 5-8. In addition, it isconstructed from a material that is better suited for coupling sections920 and 930 than second shot component 918. For example, first shotmaterial 912 may be constructed from a glass-filled nylon and secondshot material may be constructed from an unfilled nylon. Both first andsecond shots 912 and 918 electrically isolate sections 920 and 930 fromeach other.

Second shot 918 resides in a second shot retaining region 913 and withinthe gap existing between sections 920 and 930. Since second shot 918resides in the gap, it is the part visible to a user when an electronicdevice using knuckle 910 and sections 920 and 930 is fully assembled. Assuch, second shot 918 serves as a cosmetic component and can beconstructed from a material having any suitable color. For example,second shot 918 can be white, blue, purple, red, green, orange, yellow,or gray.

FIG. 10 shows a cross-sectional view of knuckle 910 taken along line A-Aof FIG. 9 in accordance with an embodiment of the invention. FIG. 10shows first shot component 912 having second shot retaining regions 913.Second shot retaining regions 913 can be cavities formed in component912 during the first shot molding process. These cavities serve ascoupling mechanisms that enable second shot component 918 to anchoritself to first shot component 912. In some embodiments, second shotcomponent 918 may be constructed from a material that is unable tochemically bond to first shot material 912 after it cures. This may bebecause it is undesirable to remelt any portion of first shot 912 afterit has cured. Thus, by leveraging second shot retaining regions 913,second shot 918 anchors itself to first shot 912 when it cures.

FIGS. 11A-B through 14A-B show illustrative views of a series of processsteps used to manufacture a two-shot knuckle in accordance with anembodiment of the invention. The figures ending with the letter A show atop view and figures ending with the letter B show a cross-sectionalview. The two-shot knuckle can be knuckle 910 of FIG. 9, though it isunderstood that any other suitable knuckle can be created.

FIGS. 11A-B show the result after first shot component 1112 has beenapplied and cured. First shot component 1112 is shown abutting theinside surface of sections 1120 and 1130 as well as protruding throughgap 1150. In addition, first shot component 1112 is shown encapsulatingcoupling structure 1140 (shown here as a bracket). Also shown as part offirst shot component 1112 are second shot retaining regions 1113.Retaining regions 1113 may be formed by a metal insert, which is held inplace during the molding process. After the mold cures, the metalinserts are removed, thereby leaving behind retaining regions 1113.

FIGS. 12A-B show cosmetic portion 1114 machined out of first shotcomponent 1112. Formation of cosmetic portion 1114 also cut sections1120 and 1130 to size so that gap 1160 of a predetermined distanceexists therebetween. Gap 1160 may have a predetermined distance that isgreater than the distance of gap 1150. FIG. 12B shows that cosmeticportion 1114 cut first shot component 1112 at an angle at its edges.FIG. 12B also illustrates how cutting tool 1170 machines away cosmeticportion 1114 by following path 1172. The angled cut provides a pocketinto which material of the second shot component can flow into duringmolding of the second shot component.

FIGS. 13A-B show how second shot component 1118 anchors itself to firstshot component 1112 using second shot retaining regions 1113. FIGS.13A-B also show second shot component 1118 extending through gap 1160.FIGS. 14A-B show knuckle 1110 after a finishing process has been appliedto remove any excess second shot 1118.

FIG. 15 shows an illustrative process for mechanically coupling twoconductive sections together with a two-shot knuckle in accordance withan embodiment of the invention. Beginning at step 1510, a firstconductive section having a first coupling structure and a first sidewall is provided. At step 1515, a second conductive section having asecond coupling structure and a second side wall is provided. The firstand second sections are secured in place so that a first gap existsbetween the first and second side walls. The first coupling structurecan be a bracket or an integrated structure. Likewise, the secondcoupling structure can be a bracket or an integrated structure.

At step 1520, a first shot component is molded into the first gap, thefirst shot component interfacing with the first and second couplingstructures to physically couple the first and second conductive sectionstogether, and comprising a second shot retaining region. The first shotcomponent can be injection molded, for example.

At step 1530, a cosmetic region is machined out of the first shotcomponent and the first and second conductive sections, the cosmeticregion comprising a second gap that exists between the first and secondside walls. Then, at step 1540, a second shot is molded into thecosmetic region.

At step 1550, a cosmetic finishing process is applied to the sectionsand knuckle. This process can involve trimming away a portion of theknuckle and polishing the sections to meet a desired aesthetic appeal.

It should be understood that the processes described above are merelyillustrative. Any of the steps may be removed, modified, or combined,and any additional steps may be added or steps may be performed indifferent orders, without departing from the scope of the invention.

The described embodiments of the invention are presented for the purposeof illustration and not of limitation.

1-20. (canceled)
 21. An electronic device, comprising: a firstconductive segment having an exterior surface and a first protrusion,the first protrusion defining an interior surface opposite the exteriorsurface; a second conductive segment having a second protrusion, thesecond conductive segment separated from the first conductive segment bya gap; and a non-conductive structure extending into the gap anddirectly contacting at least a portion of the interior surface of thefirst protrusion.
 22. The electronic device of claim 21, wherein: thefirst protrusion defines a cavity; and the non-conductive structureextends into the cavity.
 23. The electronic device of claim 21, whereinat least one normal to the exterior surface comprises: a first portionof the first conductive segment defining the exterior surface; a secondportion of the first conductive segment defining a first portion of thefirst protrusion; a first portion of the non-conductive structure; athird portion of the first conductive segment defining a second portionof the first protrusion; and a second portion of the non-conductivestructure.
 24. The electronic device of claim 21, wherein: the exteriorsurface is a first exterior surface; the interior surface is a firstinterior surface; the second conductive segment has a second exteriorsurface; the second protrusion defines a second interior surfaceopposite the second exterior surface; and the non-conductive structuredirectly contacts a portion of the second interior surface of the secondprotrusion.
 25. The electronic device of claim 21, wherein: the exteriorsurface is a first exterior surface; the second conductive segment has asecond exterior surface; and the non-conductive structure defines athird exterior surface flush with the first exterior surface and thesecond exterior surface.
 26. The electronic device of claim 21, furthercomprising: an enclosure including the first conductive segment, thesecond conductive segment, and the non-conductive structure; and atleast one electrical circuit housed within the enclosure; wherein, thefirst conductive segment and the second conductive segment are connectedto the at least one electrical circuit and configured to support anelectrical function of the electronic device.
 27. The electronic deviceof claim 21, wherein the non-conductive structure at least partiallyencapsulates the first protrusion.
 28. The electronic device of claim21, wherein the non-conductive structure comprises a plastic.
 29. Theelectronic device of claim 21, wherein the non-conductive structurecomprises a glass filled nylon.
 30. An enclosure for a portableelectronic device, the enclosure comprising: a first section formed froma first conductive material and defining both a coupling structure and afirst portion of an exterior of the enclosure; a second section formedfrom a second conductive material and defining a second portion of theexterior of the enclosure; a first material extending into the couplingstructure; and a second material, different from the first material,extending into a gap between the first section and the second sectionand defining a third portion of the exterior of the enclosure.
 31. Theenclosure of claim 30, wherein: the coupling structure is a firstcoupling structure; the second conductive material defines a secondcoupling structure of the second section; and a third material,different from the first material, extends into the second couplingstructure.
 32. The enclosure of claim 30, wherein: the first conductivematerial and the second conductive material comprises a metal; and thesecond material comprises a plastic or a nylon.
 33. The enclosure ofclaim 30, wherein: the first section comprises a first solder padproviding a first connection to circuitry within the enclosure; and thesecond section comprises a second solder pad providing a secondconnection to the circuitry within the enclosure.
 34. The enclosure ofclaim 30, wherein the first material extends between the first sectionand the second section.
 35. The enclosure of claim 30, wherein thesecond material directly contacts the first material.
 36. An enclosurefor a portable electronic device, the enclosure comprising: a firstconductive section having a first protrusion offset from a first end ofthe first conductive section; a second conductive section having asecond end and a second protrusion, wherein a first gap separates thefirst end from the second end, a second gap separates the firstprotrusion from the second protrusion, and the first gap and the secondgap have different widths; and a dielectric coupling the firstconductive section to the second conductive section and extending intothe first gap and the second gap.
 37. The enclosure of claim 36, whereinthe first protrusion is integrally formed with the first conductivesection.
 38. The enclosure of claim 36, wherein the second gap has agreater width than the first gap.
 39. The enclosure of claim 36,wherein: the first conductive section defines an exterior surface of theenclosure; the first protrusion defines an interior surface opposite theexterior surface; and the dielectric directly contacts at least aportion of the interior surface.
 40. The enclosure of claim 36, whereinthe first conductive section and the second conductive section areconfigured to support an electrical function of an electronic device.